April 2025 - Lean Built

What Is Scheduling In Production Planning?

Posted on April 30, 2025April 30, 2025 by Danny Jiménez⁩

What is Scheduling in Production Planning?

This is a really interesting topic because I’m going to use a Macro-level Takt plan to describe it. There are two different words here: schedule and production plan. Now, there are different ways to approach this, but based on the work by Todd Zabel in the book Built to Fail, a schedule is essentially the wish list or demand side of the equation, and a production plan is the merging of demand and supply — a simulation of what’s possible in line with the demand, meaning you have an overall healthy plan.

So how do you loop in scheduling (the demand side) into the supply world (what’s possible)? Here’s the answer:

Early on, during conceptual or schematic design, you create a Macro-level Takt plan. This could be done using wagons, summaries, or a simple macro phase sketch. The idea is to simulate different speeds — slowest, normal, and fastest — and strategize within the parameters you’re given, all while meeting client demands.

In this blog, I’m going to show you a real example of this macro phase sketching and how we merge these two worlds together so you have a schedule for the owner and a production plan that fits between the milestones.

Merging Demand and Supply Through Macro Phase Sketching:

I’m excited to share a real-world example from Lean Built. This approach feels almost like an art form — showing your strategic plan visually along with different options.

In the example:

The purple line represents the macro — your most reasonable promised speed (your contractual commitment).
The orange line shows what happens if we zone the project properly — your production target.
The blue line is the backup plan in case you get into trouble.

We base these on zone sizes and takt times, for instance:

Macro: 5,000 ft² zone size with a 3-day takt time.
Target: 4,000 ft² zone size with a 2-day takt time.
Backup: 2,500–3,000 ft² zone size with a 1-day takt time.

Here’s the important distinction:

The schedule is your promise to the owner — the demand side.
The production plan simulates what’s actually possible based on real production capabilities.
The backup plan prepares you to adapt if needed without hurting the workers.

This analysis even impacts cost projections. It helps developers and project managers estimate when money will be spent and ensures the budget stays intact.

Why This Analysis Matters:

Without this type of simulation:

You might promise a deadline you can’t actually meet.
Your normal production rate might barely hit the finish line, leaving no room for delays.
You won’t know if you’re financially safe until it’s too late.

Here’s a simple process you should follow:

Set your promise — the contractual finish date.
Simulate your production target — the realistic work rhythm you can achieve.
Ensure buffers exist — so you can absorb delays without panic.

By doing this, you ensure that you match the schedule with the production plan, keeping your team, your client, and your project’s success in alignment.

The bottom line is: you have to make sure your trades can actually produce according to the client’s demand. We achieve this by simulating production early, strategically zoning the project, and always planning for buffers.

Key Takeaway:

To successfully deliver a project on time and within budget, you must merge the client’s demand (the schedule) with a realistic production plan by simulating different speeds, zoning strategically, and building in buffers to handle unexpected challenges.

If you want to learn more we have:

-Takt Virtual Training: (Click here)
-Check out our Youtube channel for more info: (Click here)
-Listen to the Elevate Construction podcast: (Click here)
-Check out our training programs and certifications: (Click here)
-The Takt Book: (Click here)

Discover Jason’s Expertise:

Meet Jason Schroeder, the driving force behind Elevate Construction IST. As the company’s owner and principal consultant, he’s dedicated to taking construction to new heights. With a wealth of industry experience, he’s crafted the Field Engineer Boot Camp and Superintendent Boot Camp – intensive training programs engineered to cultivate top-tier leaders capable of steering their teams towards success. Jason’s vision? To expand his training initiatives across the nation, empowering construction firms to soar to unprecedented levels of excellence.

On we go

What Are The Things To Consider In Production Planning?

Posted on April 28, 2025April 28, 2025 by Danny Jiménez⁩

Key Things to Consider in Production Planning

In this blog, I want to talk to you about a kind of lost — or maybe never fully developed — art in production planning.

In a typical production plan, you’ll see the different phases of the project laid out with flow, usually in a time-by-location format. We all know the standard elements: an executive summary, milestones, the first 120 days of administrative and mobilization work, and long-lead procurement schedules.

But here’s something you rarely — if ever — see on a production plan: the Trade Partner Preparation Process.

The Trade Partner Preparation Process:

The Trade Partner Preparation Process is about managing the time it takes to get a trade partner through buyout, pre-mobilization, their pre-construction (or preparatory) meeting, and into their first zone of work. Just like procurement, these steps need to be leveled — you can’t stack them all at once. You can’t have 30 pre-mobilization meetings in a single week without overloading your team. This leveling must be managed within your actual production plan.

If you implement this Trade Partner Preparation Process, you’ll be successful on your project because your trades will be queued up and fully supported with everything they need.

Now, let’s dive deeper into what this process looks like.

How It Works:

I walk through how I set this up inside InTakt — a planning tool that’s become one of my favorites (I even like it better than Excel for Takt planning).

If you’ve worked for Hensel Phelps, you might recognize this as a variation of their Six-Step Process. Others call it the Quality Process. Whatever you call it, it’s crucial.

Here’s the basic flow:

Teeing/Purchasing Phase: This happens before reaching a fully executed contract.
Pre-Mobilization Meeting: Scheduled within two weeks of signing the contract, ensuring the trade partner has time to prepare submittals, RFIs, and other documentation.
Pre-Construction (Preparatory) Meeting: Confirm that the foreman and superintendent are 100% ready to begin work. Ideally, this happens two to three weeks after the pre-mob.
First In-Place Inspection: Conducted as soon as the first work is ready.
Follow-Up Walks: Continue to monitor the quality and progress.
Rolling Completion List & Final Walk: Ensure all scopes are completed before trade partners demobilize.

The key pattern here:
➡️ Plan it first.
➡️ Build it right while you’re there.
➡️ Finish as you go.

Using InTakt to Visualize and Manage It:

Inside InTakt, you can visualize the phases: Project Management, Bidding Process, Permitting, and the Trade Partner Preparation (labeled TP3). This helps ensure you have enough time before work starts for all necessary steps: pre-mob meetings, pull planning, pre-construction meetings, and prep work.

For example, if civil work is starting soon, you’ll want to ensure the pre-con meeting is done before that start date — and not have it crammed in last minute.

The beauty of this system is that it not only keeps your production plan flowing, but also lets you level out meetings. If you notice you have too many pre-mob and pre-con meetings scheduled at once (say, 23 meetings in two weeks), you’ll instantly see the bottleneck and can adjust.

Managing the Trade Partner Preparation Process within your production plan prevents overwhelm and keeps the project moving smoothly.

The bottom line: Don’t forget to manage and level your Trade Partner Preparation Process.
If you don’t, your team will get overloaded — especially when submittal reviews and other internal processes layer on top.

Key Takeaway:

In production planning, success isn’t just about scheduling work — it’s about carefully managing and leveling the Trade Partner Preparation Process to ensure trade partners are fully prepared, supported, and ready to perform when their time on-site begins.

If you want to learn more we have:

Discover Jason’s Expertise:

On we go

Batching vs. OPF

Posted on April 25, 2025April 25, 2025 by Danny Jiménez⁩

Batching vs. One Piece Flow: Which is the Best Approach for Your Projects?

If you’re familiar with the concepts of batching and one-piece flow, you may have heard conflicting opinions about which one is faster or more efficient. At first glance, batching might seem like the faster approach, but when we dive into the details, the truth may surprise you. In this blog, I’ll explain both concepts and why one-piece flow is often the better approach, especially when it comes to efficiency and productivity.

What is Batching?

Batching refers to completing a single step for multiple items at once. Think of it like making pancakes – you would cook 10 pancakes, then butter them all, and finally add syrup to all of them before serving. You’re completing each step in bulk, which is a common practice in many industries.

However, in construction or other industries where precision and speed are crucial, batching can slow things down, and here’s why. When you batch processes, you’re performing the same task for a large group before moving on to the next step. This means you’re working in large chunks and dealing with delays between each step.

What is One Piece Flow?

One piece flow, on the other hand, is all about focusing on one task at a time. Instead of completing a step for multiple items, you do it for just one and move on to the next task as soon as it’s finished. If we use the pancake example again, you’d cook one pancake, butter it, add syrup, and serve it – then move on to the next one. This might seem slower at first, but in fact, it’s far more efficient.

In construction, one piece flow might mean completing one process fully before moving on to the next, without waiting for all items to be processed. This ensures that each task is finished correctly and promptly.

Why One Piece Flow is Faster:

Although we’ve all been taught that batching is faster, the truth is that one piece flow leads to faster completion times. Why? It’s all about reducing context switching and eliminating unnecessary delays.

In one piece flow, as you focus on completing each step individually, you avoid the interruptions and delays that come from switching between multiple tasks. Instead of waiting for one part of a process to finish before moving on, you’re completing each task quickly and without delay.

A Real-World Example:

Let’s look at a company that specializes in exterior inspections and consulting. Initially, they were running late on reports every day because they used batching. They would do one inspection, but leave the report and follow-up email for later. This would cause them to fall behind on tasks throughout the day, leading to delays.

Once they switched to one piece flow, they completed the inspection and report for each job before moving on to the next. This shift allowed them to complete more inspections each day, reduce delays, and ultimately get their reports out on time. The results were remarkable, and the team was happier and more productive.

The Benefits of One Piece Flow:

There are several key benefits to using one piece flow:

Faster Completion: Focusing on one task at a time eliminates wasted time and allows for quicker completion.
Reduced Errors: By completing each task fully, you’re able to ensure that everything is done right before moving on.
Improved Efficiency: One piece flow helps streamline processes, reducing bottlenecks and delays.

Tools and Resources to Help You Implement One Piece Flow:

If you’re looking to implement one piece flow in your operations, there are several resources that can help. From specialized software to insightful articles and blogs, you can find plenty of tools to assist in transitioning from batching to one piece flow.

Conclusion:

Ultimately, adopting one piece flow can drastically improve the speed and efficiency of your processes. Whether you’re working in construction or any other industry, focusing on completing one task at a time, rather than batching, will save you time and increase your overall productivity.

If you want to learn more we have:

Discover Jason’s Expertise:

On we go

Quantities For Estimating

Posted on April 25, 2025April 25, 2025 by Danny Jiménez⁩

Why Quantity Takeoffs Are Essential for Accurate Estimating

In this blog, we’re diving into one of the most important—yet often overlooked—parts of the estimating and bidding process: quantity takeoffs. I talk a lot about estimating, bid leveling, and selecting the right trade partners, but none of it works if we don’t have accurate quantities.

The Problem: No Control Estimate = No Real Comparison

I was recently talking with a great general contractor who shared something telling: “We do a good job inviting trade partners to price the work, but we don’t do a good job yet of getting quantities or having control estimates.” That’s a common issue.

When bids come in without a control estimate, you don’t really know if a price is high or low. You’re flying blind. To fix that, you need a baseline—an independent quantity takeoff—to compare each bid against.

Why Many Teams Struggle:

Large companies often have reduced capacity due to heavy workloads.
Smaller companies might not have the technical capability in-house.

Either way, the task is necessary. You must know your quantities.

A Simple Fix: Third-Party Help or Software:

Here’s the good news: You don’t have to do it all yourself. There are affordable services and tools that can help with takeoffs. On a recent Lean Built project, we were short on time and used a third-party to perform takeoffs—and they nailed it. We double-checked and hit our budget targets. It wasn’t even that expensive.

The Core of the Issue: Bid Validation:

Trade partners are great, but even the best of them can submit bids with:

Incorrect quantities.
Incomplete scope.
Misleading per-square-foot numbers (especially in development, where usable vs. total square footage varies).

That’s why control estimates and quantity takeoffs are crucial. They help us avoid comparing apples to oranges.

My Key Advice: Build a Schedule of Quantities:

Here’s what I recommend:

List the critical scope items that will impact pricing.
Reference quantity survey manuals (many companies have them).
Do takeoffs for each key item so you can validate trade partner bids.
Leverage your designers. They already have much of this info—cut/fill volumes, material estimates, and more.

Tools You Can Use (Recommended Software):

I asked ChatGPT to help me find the most common quantity takeoff tools in construction. Here are a few great options:

PlanSwift.
Bluebeam Revu.
STACK.
Autodesk Takeoff.
On-Screen Takeoff.
Procore Estimating.

These tools can save time, reduce errors, and help you create internal benchmarks to compare against trade bids.

Final Thoughts:

This isn’t about mistrusting your trade partners. It’s about doing your job right—verifying scope, square footage, and quantities before locking in pricing. That’s how you prevent mistakes and set up your project for financial success.

If you want to learn more we have:

Discover Jason’s Expertise:

On we go

How To Make A Production Plan

Posted on April 25, 2025April 25, 2025 by Danny Jiménez⁩

How to Make a Production Plan – A Real Example from the Field

I’m super excited to share this blog with you because it’s all about how we built a production plan for a $120 million multifamily project—our first one at LeanTakt. Everything for this project is organized in a powerful software tool called InTakt.

But instead of just talking about production planning, I want to show you how it all comes together—from executive summaries and milestones to mobilization items, deferred submittals, long lead procurement, and the trade partner preparation process.

We’re going to walk through how to kick off production for site work, foundations, structure, interiors, and more. Seeing it all in place is key—so let’s not just talk about procurement or trade partner prep, let’s actually see it.

The Software We Use:

We use InTakt—our preferred Takt planning software. We’ve researched a lot of options over the years, and this one stands out for its simplicity, user-first design, and rapid development. The second half of this blog will show you how to create a production plan using InTakt.

Key Elements of the Production Plan:

Here’s how the software layout works:

Timeline on Top: This is a norm-level production plan—organized day-by-day.
Phases, Areas, and Zones on the Left: This layout helps you visualize everything clearly.
Full Functionality: You can customize and export your plan into CPM (Critical Path Method), which is a game changer.

Now let’s talk structure. The plan starts with:

Executive Summary & Milestones.
Bidding Process.
Trade Partner (TP) Preparation.
Procurement & Deferred Submittals.

Each section is logically tied into the production plan and exports with that logic. That means it’s not just for planning—it’s for managing real project execution.

Leveraging AI with ChatGPT:

Here’s something unique we’ve started doing: using ChatGPT to help identify long lead items and potential deferred submittals before the design is even finished.

We’ll ask ChatGPT something like:

“Hey, based on a multifamily building in this location, what are potential long lead items? Give me prep, review, and approval lead times.”

Even if it’s not 100% accurate, we’re managing it ahead of time. If something turns out irrelevant, we delete it. Simple. This proactive approach helps us stay ahead and reduce risk.

Site & Make-Ready Activities:

Within the production plan, we’ve incorporated:

Long lead procurement.
Deferred submittals.
Trade partner prep.
General requirements.
Critical timelines (e.g., temporary power sign-up, trailer setups).

After that, we move into civil work, foundations, exteriors, and interiors—all in a structure you’d expect from a solid Takt plan.

How the Production Plan Comes Together:

Here’s how to build a great production plan:

Create the Master Schedule: This is your macro-level Takt plan.
Pull Plan the First Sequence: For example, Zone A on Floor 1—this starts with input from trade partners.
Use Multi-Rhythm Takt Planning: Different trades can run on different takt times. For example, Gypcrete may have its own rhythm separate from framing or drywall.
Time-by-Location Format: Organize by zone and phase to maintain clarity.
Include Trade Flow: Ensure your sequencing reflects how work actually flows across zones.

The goal is to create a plan with the right number of zones, the right sequence, and realistic buffers to handle risk.

Buffers & Milestones:

At the bottom of the plan, we always include a buffer. It might look large, but it’s necessary to account for risk, especially when aligning with your Substantial Completion Date.

So:

Add buffers strategically.
Ensure your milestones are clearly defined.
Understand how your plan flows from the end goal backward.

From End Date to Start Date:

We start with the end (substantial completion), then work backward to identify:

When interiors and exteriors need to wrap up.
When concrete and civil must begin.
When procurement and bidding must be complete.

For example, if our notice to proceed is May 19, everything—TP prep, deferred submittals, procurement—must be queued up to hit that start date.

The Process Recap:

Start with the end date.
Define zones and layout.
Insert buffers for risk management.
Work backward from completion to procurement.
Make sure make-ready activities start on time.
Use Takt planning software to visualize and manage it all.

We’ve used this system across many projects and it consistently leads to success. The key? Make a plan to succeed—and start on time.

Key Takeaway:

A successful production plan starts with the end in mind—by defining your substantial completion date, building in the right buffers, and working backward to align procurement, trade partner preparation, and make-ready activities. Using Takt planning software like InTakt and leveraging tools like ChatGPT allows you to visualize, manage, and execute your plan with clarity and confidence—all while staying ahead of risk.

If you want to learn more we have:

Discover Jason’s Expertise:

On we go

Lift Drawings For Starting Construction

Posted on April 22, 2025April 22, 2025 by Danny Jiménez⁩

Why You Need Lift Drawings to Start Construction the Right Way

No matter what type of project you’re working on — whether it’s a hospital, lab, airport, steel or concrete structure, or even a wood-framed multifamily building — lift drawings are essential for starting construction effectively.

In this blog, I’m breaking down what lift drawings are, why you need them, and how we’re using them on our current $120 million Lean Built multifamily project to set ourselves up for success.

What Are Lift Drawings?

A lift drawing is a coordination tool that pulls information from multiple drawing sets into one unified document. These drawings allow your team to see how all the pieces fit together — from structural to architectural to civil — so you can build with confidence.

Contrary to popular belief, you don’t need to be self-performing the work or have field engineers on staff to benefit from lift drawings. These are just as critical for GCs managing subcontractors as they are for self-performers.

Real Examples from the Field:

Let’s take a closer look at how we’re implementing lift drawings at our West Fillmore project.

Dimensional Coordination Drawing: Our team literally drew every wall from the plans (not CAD or Bluebeam) to verify dimensions, anchor bolt locations, hold-downs, and edge of slab details. We uncovered 45+ issues that would’ve become RFIs later — all caught during this drawing process. Now, when we’re out in the field, we can QC the edge of slab, bolt locations, and more with precision using total station layouts.
Primary Control Plan: We created a site-wide lift drawing including basis of bearings, property corners, and northing/easting coordinates for each of the 9 buildings. This ensures our hired surveyors can tie everything back to known coordinates and establish reliable control for layout.
Structural QC Modeling: Because wood framing can be ambiguous and dependent on the framer’s experience, we built lift drawings and models of two full units to ensure accurate QC. We know exactly how hold-downs, post-tension slab, and anchor bolts should look — and can confirm it during inspections.
Additional Lift Drawings: Beyond structure, we’re also doing lift drawings for roof slopes, ceiling heights, MEP coordination, utility cut sections, and site flatwork — especially to ensure slopes don’t exceed tolerances.

Why Lift Drawings Matter:

Lift drawings do three things:

Help you learn the building: You can’t build what you don’t understand.
Reveal problems early: Issues get surfaced before construction, not during.
Provide trades with buildable visuals: When everything’s clearly shown, your team knows what to do.

Whether you’re on a remodel, data center, or residential project — lift drawings are a must-have in pre-construction. They’re how you prevent quality issues, go faster, and create a strong foundation for success.

If you want to learn more we have:

Discover Jason’s Expertise:

On we go

What Is Pre-Construction Timeline Planning?

Posted on April 21, 2025April 21, 2025 by Danny Jiménez⁩

Mastering Pre-Construction Timeline Planning

What is preconstruction timeline planning—and why is it so critical? In this blog, we’ll break down the importance of managing multiple timelines during pre-construction to ensure your project stays on track and flows smoothly from start to finish.

You might have a solid production plan that outlines when construction should begin and how to maintain flow, but behind that plan are several critical timelines. Think switchgear, permanent power, internet access, long-lead material procurement, exterior finishes, elevators—the list goes on. Each of these elements must be tracked and managed with precision.

As Fred Strasser from Oakland Construction wisely put it, “Don’t fall asleep on that timeline.” Managing these components is truly an art form—an essential focus during the pre-construction phase.

Let’s dive into how we approached timeline management for our West Fillmore project in Buckeye, Arizona. Using Miro (although tools like Excel, Visio, Bluebeam, or even Microsoft Whiteboard also work), we visually mapped out every timeline—complete with team responsibilities, key phases, and critical dates.

On the left side of the board, we placed photos of those accountable for various tasks, and across the top, we charted time. This macro-phase Takt plan covered the civil phase, clubhouse foundations, and multiple buildings—shaping the structure of our production plan.

But here’s where many teams go wrong: they overlook the importance of managing timelines in this early phase. Owners, design teams, or even general contractors often fail to realize the value of trade partner input or early GC involvement in shaping and aligning timelines during pre-construction.

Let’s consider one key timeline: electrical distribution. We tracked the timeline for releasing switchgear—from the desired date to the last responsible moment. The coordination with APS (Arizona Public Service) was tightly synced to ensure we’d receive permanent power on schedule.

By tracking this visually, we knew when design details and approvals were needed, and we could proactively drive those deadlines with the design team. The result? We hit our release date and stayed on course.

And when APS announced a change in responsibilities—introducing a timeline shift—we quickly compared our original visuals with the updated projections. That gave us a real-time way to alert the owner and adjust accordingly. It became a navigational tool—a map and compass—so we weren’t just reacting, we were steering.

This is the essence of timeline planning: pairing your production plan with critical long-lead timelines, and never letting those timelines out of your sight.

Key Takeaway:

Successful pre-construction requires more than just a solid production plan—it demands proactive timeline planning for every critical element. By visualizing and managing these timelines early, teams can prevent delays, drive coordination, and keep the entire project on track from day one.-

If you want to learn more we have:

Discover Jason’s Expertise:

On we go

How Do I Know I Have The Right Logistical Sequence?

Posted on April 20, 2025April 20, 2025 by Danny Jiménez⁩

How to Sequence Buildings with Site Utilities Using Week-by-Week Analysis

In this blog, I’m going to walk you through a real-world example where we were faced with a critical question: What building should go first in sequence with the site utilities? You’ll see how we made that determination using a structured method, including the key steps and tools that led us to a data-driven decision.

The Big Question: What Goes First?

Let me set the stage: this was our first project in a multi-phase development. We had garden-style, three-story walk-up multifamily buildings, a clubhouse, and a pool—all part of phase one. It seemed simple at first glance, but when it came down to determining which building to start with, things got complex fast.

Should we go Building 1 → 2 → 3? Or start elsewhere? And what about the clubhouse? All of this had to be planned around ongoing site work phasing in different directions. Verbal back-and-forth wasn’t cutting it. Even with my experience phasing much more complex sites, this stuff is still tough to visualize without the right tools.

The Solution: Week-by-Week Analysis

That’s where week-by-week analysis came in. Huge shout out to Luis, who spearheaded this effort. Here’s what he did:

Mapped out the site utilities on a plan.
Overlaid the plan with building locations.
Plugged the actual production plan into a Takt format below the visual.

The result? A clear time-by-location diagram showing exactly what would be happening each week across the site.

Breaking It Down:

Luis looked at the plan week by week—what’s happening on Week 1, 2, 3, all the way through Week 18. He added internal notes to indicate what he was analyzing and how each scenario would play out.

The visuals made it obvious:

Was Building 2 accessible in time?
Would Building 3 create conflicts?
How early could we get to the clubhouse?

This level of detail gave us the confidence to finalize the building sequence and integrate it directly into the bidding documents.

From Guesswork to Data-Driven Planning:

This process didn’t take days—it took a couple of hours. And it eliminated guesswork. The final logistics plan, including zone breakdowns and building sequence, was based on clear, visual analysis.

So, ask yourself: Is your project plan based on hard data or just intuition?

Why It Matters:

I’ve never seen a complex site—tight layout, basements, concrete-heavy projects—succeed without this kind of day-by-day or week-by-week mapping. The human brain just isn’t wired to visualize it all. You have to draw it out and validate it visually.

Key Takeaway:

When sequencing buildings around site utilities, don’t rely on guesswork—use a week-by-week visual analysis to make data-driven decisions that clarify access, avoid conflicts, and strengthen your production plan.

If you want to learn more we have:

Discover Jason’s Expertise:

On we go

Takt Introduction – Takt University Course – Video 1

Posted on April 17, 2025April 17, 2025 by Danny Jiménez⁩

Introduction to the Takt Production System: A Smarter Way to Build

Welcome to this blog where we introduce the Takt Production System—a revolutionary scheduling method designed to bring rhythm, consistency, and flow to construction projects. This approach, pioneered by LeanTakt, blends the best of lean tools, line-of-balance, Gantt, CPM, and location-based scheduling into a powerful, people-centered system.

We’ll walk you through the core concepts, how it all fits together, and how to start applying it on your projects.

What is the Takt Production System?

At its core, the Takt Production System maps out construction flow through zones using a time-location matrix. Time runs horizontally, while zones or value-receiving units are listed vertically. The result? A visual, one-page schedule that aligns all three types of construction flow:

Workflow.
Trade flow.
Zone flow.

This system isn’t just visual—it’s actionable. It stabilizes your project so you can optimize it. And most importantly, it allows for trade leveling, buffer creation, and seamless coordination with the Last Planner System.

The Orchestra Analogy:

Think of Takt like sheet music. Takt sets the rhythm, and your trades are the musicians. The general contractor is the conductor—ensuring everyone plays in sync. Trades can only be effective individually if they’re effective together, and it’s the GC’s job to harmonize the entire ensemble.

Takt’s Role in the Integrated Production Control System:

Takt isn’t a standalone method. It’s one of three core systems that form the Integrated Production Control System:

First Planner System – Designs the project, aligning the team, culture, and supply chain.
Takt Production System – Executes and simulates project flow on-site.
Last Planner System – Enables collaborative, commitment-based weekly planning with trades.

Together, these systems work to bring your schedule to life.

Why Time by Location is Essential:

The time-location matrix is powerful because it reveals diagonal trade flow—a key sign of an optimized schedule. When trades move in consistent rhythms across zones, it’s the fastest and most efficient way to complete work.

This layout also helps spot bottlenecks. If one trade or zone is slowing things down, you can adjust, rezone, or rebalance your crews without crashing the schedule.

Types of Takt Plans:

There are two main types:

Single-Train Takt Plans: One crew flows through zones in sequence.
Multi-Train Takt Plans: Multiple crews move through zones at different rhythms. This focuses more on resource efficiency than standard rhythm.

Both are valid and depend on your project’s needs.

Production Laws at Play:

Takt aligns with key production laws:

Little’s Law: Smaller zone sizes = faster project completion.
Law of Variation: Consistency and rhythm reduce delays.
Law of Bottlenecks: Identify and address the most limiting factors.
Kingman’s Formula: Balances work time, variation, and productivity for optimal flow.

Why Rezoning Matters:

Rezoning (breaking larger zones into smaller ones) can drastically shorten project durations without reducing individual trade durations. This is a core application of Little’s Law and one of Takt’s major advantages over traditional scheduling.

Advanced Work Packaging Meets Takt:

Takt supports advanced work packaging by enabling reverse planning—from installation back to design. Instead of pushing trades to work faster, Takt helps redesign work packages for flow and efficiency.

The Push vs Flow Simulation:

We tested the difference between pushing and flowing using a construction game simulation. The takeaway?

Pushing (more labor, less planning) caused delays, roadblocks, and higher costs.
Flowing (more planning, consistent rhythms) led to faster completions, fewer issues, and lower costs.

Even when slowed down unrealistically, flowing outperformed pushing. More labor ≠ faster results. In fact, it often creates inefficiencies and burnout.

Why CPM Falls Short:

While CPM (Critical Path Method) has its place, it often leads to:

Increased work-in-progress (WIP).
Disobeying production laws.
Disrespecting the workforce.

Takt, on the other hand, promotes:

Respect for people.
Stability and flow.
Total team participation.
Continuous improvement.

CPM creates black-and-white plans with no visibility, no rhythm, and no room for improvement. Takt flips the script by designing systems that empower field teams.

Tools & Resources to Get Started:

To help you on your Takt journey, we’ve developed a full ecosystem of resources:

Takt Guidebook.
YouTube Training (search “Jason Schroeder” or “LeanTakt”).
Role-based Miro Boards.
Takt Production System Books.
Podcasts and Blog Posts.

Final Thoughts:

The Takt Production System is not just a scheduling method—it’s a movement. It’s a philosophy built on flow, respect, and rhythm. It’s how we build capacity without chaos. It’s how we get people home safe.

As Takt grows in popularity, we must protect its integrity. It should never become just another tool for profit without purpose. It’s a system for people, not against them.

So, if you’re ready to leave behind the outdated practices of pushing and embrace a flow-driven, people-focused construction future—welcome aboard. This is just the beginning.

If you want to learn more we have:

Discover Jason’s Expertise:

On we go

What Is The Last Planner System PPC?

Posted on April 17, 2025April 17, 2025 by Danny Jiménez⁩

Understanding Percent Plan Complete in the Last Planner System

What is Percent Plan Complete (PPC), and why does it matter in the Last Planner System?

In this blog, we’ll dive into how to measure your PPC, what it means when working with CPM or Takt, and the key performance indicators (KPIs) that can help your project team truly win. You’ll also see real examples from our book that will clarify concepts you may have never encountered before.

What is Percent Plan Complete?

PPC, also known as Percent of Promises Complete, is a metric used to track how many planned tasks were actually completed as promised. It’s calculated using a simple formula:

PPC = (Completed Activities ÷ Promised Activities) x 100

For example, if you planned 10 activities and completed 8, your PPC is 80%.

In the traditional CPM-based Last Planner System, you typically aim for a PPC above 80%. Hitting 100% might indicate you’re playing it too safe, a concept known as sandbagging. However, with Takt, your goal should be to consistently hit 100%, since production leveling and targets have already been optimized.

How PPC Works on the Jobsite:

Let’s say on January 16th, your daily plan had six promised tasks. If only five were completed, your PPC would be:

5 ÷ 6 = 83%

But it doesn’t stop at just tracking the number. It’s critical to understand why a task wasn’t completed. That’s where root cause analysis comes in.

Root Cause Analysis: Constraints vs. Roadblocks:

Every time a task isn’t completed, you need to ask: was it a constraint or a roadblock?

Constraints are system-level problems.
Roadblocks are physical or immediate issues in your way.

We provide a comprehensive list of both, backed by solid research, to help you diagnose problems effectively. Once identified, you can adjust your planning system, trade flow, zones, or site operations to avoid those issues in the future.

From Macro to Micro: Takt Planning in Action:

Starting at the macro level with your overall Takt plan, you drill down to the norm level and then to your look-ahead plan. This plan helps you remove roadblocks in advance and prepare activities to be “make ready.”

Your weekly work plan lives within this structure. It identifies task handoffs and sets the stage for measuring PPC at the daily level. By the time you get to your day plan, it should be mostly free of constraints and roadblocks.

Improving PPC Through Daily Review:

When you review the daily plan and mark off what was completed, you not only get your PPC percentage—you also pinpoint specific missed tasks and analyze what caused the variance.

If two tasks were missed, ask:

What happened?
Was it a constraint or a roadblock?
What can we change in the system to prevent this next time?

This constant feedback loop improves your workflow and supports lean construction principles.

Beyond PPC: Other KPIs You Can Track:

While PPC is important, it’s just one of four KPIs we recommend tracking in the Takt Production System:

Perfect Handoff Percentage – How often you hit the planned handoffs in your weekly work plan (target: 80%+).
Remaining Buffer Ratio – Do you have enough time buffer to absorb delays?
Roadblock Removal Average – On average, how many days before impact are roadblocks removed? The higher this number, the better.

These metrics together give a more complete picture of project health and flow efficiency.

Wrapping Up:

To summarize:

PPC measures the percentage of promised tasks completed.
For CPM-based systems, aim above 80%. For Takt, target 100%.
Always follow missed tasks with root cause analysis.
Identify whether the issue was a constraint (system problem) or a roadblock (immediate obstacle).
Use additional KPIs like handoff percentage and roadblock removal average to improve performance further.

Key Takeaway:

Percent Plan Complete (PPC) isn’t just a number—it’s a powerful indicator of reliability in your planning system. By tracking PPC and analyzing missed tasks through root cause analysis, you can uncover system weaknesses, eliminate recurring roadblocks, and drive consistent improvement in project performance.

If you want to learn more we have:

Discover Jason’s Expertise:

On we go

Month: April 2025

What Is Scheduling In Production Planning?

What Are The Things To Consider In Production Planning?

Batching vs. OPF

Quantities For Estimating

How To Make A Production Plan

Lift Drawings For Starting Construction

What Is Pre-Construction Timeline Planning?

How Do I Know I Have The Right Logistical Sequence?

Takt Introduction – Takt University Course – Video 1

What Is The Last Planner System PPC?

Subscribe Now !

The Foundation of Construction Excellence

© 2025 Leanbuilt.us All Rights Reserved. |